Weber SMOKEY MOUNTAIN COOKER 63230 User manual

SMOKEY MOUNTAIN
COOKER™SMOKER
63230
19 inch
(49 cm)

2
DO NOT DISCARD. THIS CONTAINS IMPORTANT
PRODUCT DANGERS, WARNINGS AND CAUTIONS.
Note - Do not operate this smoker until
you have read this owner’s guide.
OWNER’S GUIDE AND COOKBOOK

3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Helpful Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Brine Cure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Cooking Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15
Recipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-23
Barbecuing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-26
Steaming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4
 DANGER
Failure to follow the Dangers, Warnings and Cautions contained
in this Owner’s Manual may result in serious bodily injury, death,
or fire causing damage to property.
 WARNINGS
 This smoker is designed for outdoor use only. If used indoors,
toxic fumes will accumulate and cause serious bodily injury or
death.
 Do not add charcoal lighter fluid or charcoal impregnated with
charcoal lighter fluid to hot or warm coals. Cap starter fluid after
use, and place a safe distance away from the barbecue.
 Do not use gasoline, alcohol, or other highly volatile fluids to
ignite charcoal. If using charcoal lighter fluid, remove any fluid
that may have drained through the bottom vents, before lighting
the charcoal.
 Do not leave infants, children, or pets unattended near a hot
smoker.
 Do not attempt to move a hot smoker.
 Do not use this smoker within five feet of any combustible
material.
 Do not use this smoker unless all parts are in place.
 Do not remove ashes until all coals are completely burned out
and are fully extinguished.
 Do not wear clothing with loose flowing sleeves while lighting or
using the smoker.
 Do not use smoker in high winds.
 Keep the smoker in a level position at all times.

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Combustion by-products produced when using this product
contain chemicals known to the state of California to cause
cancer, birth defects, or other reproductive harm.
Remove the lid from the smoker while lighting and getting the
coals started.
Always put charcoal on top of the charcoal grate and not
directly into the bottom of the bowl.
Never touch the cooking or charcoal grate, or the smoker,
to see if they are hot.
Barbecue mitts or hot pads should always be used to
protect hands while barbecuing or adjusting the vents.
Use proper barbecue tools with long, heat-resistant handles.
To extinguish the coals, place the lid on the bowl and close all
vents. Do not use water, it will damage the porcelain finish.
To control flare-ups, place lid on smoker. Do not use water.
Handle and store hot electric starters carefully.
Keep electrical cords away from the hot surfaces of the smoker.
Lining the bowl with aluminum foil will obstruct the air flow,
instead use a drip pan to catch drippings from meat when
cooking by the Indirect Method.
Using sharp objects to clean the cooking grate or remove ashes
will damage the finish.
Using abrasive cleaners on the cooking grate or the smoker
itself will damage the finish.

6
Check Package Contents
You should have received the parts listed at right.
While we give much attention to our product, an
occasional error may occur. If a part is missing, do
not go back to the store. Call the Weber-Stephen
Products Customer Service Center toll-free at
1-800-446-1071 to receive immediate assistance.
Lid
Three legs
Center ring
Charcoal chamber
Bowl
Water pan
Door assembly
Four grill straps
No-handled cooking grate
Charcoal grate
Handled cooking grate
Hardware Pack Contents:
14 - 1⁄4-20 x 5⁄8" screws
14 - 1⁄4-20 nuts
8 - Fiber washers
6 - 1⁄4" steel washers
Assemble Legs
You will need: bowl, three legs, six screws, six steel washers, six nuts, an adjustable wrench and
a screwdriver.
Set bowl on the ground. Place leg against bowl and insert one screw into each end of leg. Slip
a steel washer over each screw, add a nut and hand tighten.
Repeat this for the other two legs.
With the three legs in position, tighten
assembly using an adjustable wrench
and screwdriver.
1
2

7
Assemble Charcoal Grate
and Charcoal Chamber
You will need: charcoal grate and charcoal chamber.
Set charcoal grate into bowl. Set charcoal chamber
on charcoal grate.
Attach Grill Straps to Center Ring
You will need: four grill straps, eight fiber washers, eight screws, eight nuts, center ring, an
adjustable wrench and screwdriver.
Place a fiber washer on each of the screws and insert into each hole in center ring, with heads
of screws on the outside. Place grill straps inside the ring over the screws, making sure the
two “ledges” are at the bottom. Place a nut on each of the screws and tighten securely with an
adjustable wrench and screwdriver.
3
4

8
Install Center Ring and Bowl
You will need: center ring assembly from
Step 4 and bowl assembly from Step 3.
Place center ring assembly onto bowl.
Install Door Assembly
You will need: door assembly and center
ring to bowl assembly.
Holding door assembly on a slight angle,
place door assembly into opening in
center ring. To open or close, turn knob.
5
6

9
7
Complete Assembly
You will need: lid, water pan, no-handled cooking
grate and handled cooking grate. Place water pan
on the bottom ledge of grill strap. Place
no-handled cooking grate on middle ledge of
strap. Place handled cooking grate on very top
ledge of strap. Set lid on top.
Steaming and Barbecuing
To steam: arrange the charcoal grate, charcoal
chamber, and water pan on the middle ledge grill
strap. Place no-handled cooking grate on top of
the water pan. Place handled cooking grate aside.
To barbecue: arrange the charcoal grate and
charcoal chamber on the middle ledge grill strap.
Set aside no-handled cooking grate and water
pan. Place handled cooking grate on very top
ledge of strap.
8

10
Helpful Hints
Please read all instructions before using your smoker.
• Always cook with the cover on your smoker.
• Use tongs for turning meats to avoid piercing meat and losing natural juices.
• Resist the temptation to look at the foods during cooking time—every time the lid is lifted it
will be necessary to add 15 minutes to the cooking time.
• Use a meat thermometer to determine the internal temperature of meat—it should be inserted
into the thickest part of the meat and should not touch fat or bone.
• Charcoal should be stored in a dry place—damp charcoal will not burn well.
• Always use barbecue mitts or hot pads to protect your hands.
• Adjust vents as indicated for each method of cooking in your smoker:
Smoking—all vents partially closed.
Barbecuing—all vents wide open.
Steaming—top vent closed, bottom vents open.
• All vents should be wide open when preparing the fire.
• Close all vents to extinguish the coals when you are finished cooking. Do not use water to
extinguish coals as it may damage the porcelain finish.
• There are many variables that influence smoking, fortunately most of them can be controlled
by the person doing the cooking. However, there are some things that we cannot control,
such as weather, wind and altitude. So, to be on the safe side, add extra time to your cooking
schedule when necessary, usually half to 1 hour is adequate.
• Smoker should be placed on a level heat proof surface away from buildings and out of the
general traffic path. The smoker is for outdoor use only and not recommended for use on
carpeted surfaces. Since the aroma of smoke can linger it is best to find a place away from
the house to do your smoke-cooking.
• Experiment with different varieties of wood and amounts used. You can also add bay leaves,
garlic cloves, mint leaves, orange or lemon peel and various spices to the charcoal for added
flavor. Keep a record of your experiments—it’s easy to forget what you did last time.
Note: Do not use charcoal that has been impregnated with a starter fluid in your smoker. This is
especially important when adding charcoal during the cooking time, because it can give
an unpleasant taste to your food.

11
Cleaning
It isn’t necessary to clean the inside walls of your smoker, however, if you wish, they may
be wiped down occasionally. The outside of the unit may be cleaned with a sudsy cloth and
rinsed with a damp cloth.
If you use aluminum foil to completely cover the water pan it will aid the clean-up chore.
Grease tends to build up on the inside and outside of the water pan. When the grease
build-up is baked onto the pan it may flake off—this is not porcelain flaking off—it is
hardened, baked-on grease and can be cleaned off with a spray-on oven cleaner. Follow
the manufacturers directions on oven cleaner.
Frequently remove ashes from the bottom section of the smoker.

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Getting Started
• Remove top and center ring before starting the fire. Open all vents.
• Fill charcoal chamber with the amount of charcoal recommended on chart for food being
cooked. Heap charcoal in center of grill. Ignite the charcoal.
• When the coals have a light coating of gray ash (about 30 minutes) spread them evenly
across the inside of the charcoal chamber.
• Place the water pan in position on the lower bracket of the center ring. Fill pan with hot tap
water.
• Put the lower cooking grill in place on bracket above water pan. The 181⁄2" cooking grill should
be positioned on the top bracket.
• Carefully set the center ring in place on top of the bottom section of the smoker.
• Arrange food in a single layer on the cooking grills leaving space between each piece of food.
(Both grills may be used for food.)
• Open door on front of smoker to place wet wood chunks on top of the hot coals.
• Partially close all vents while smoke-cooking. Use barbecue mitts to protect your hands while
adjusting the vents.
• PIace recommended amount of wood chunks in a pan of water to soak at least 1 hour
before using.
• Shake excess water off wood chunks before placing them on top of the hot coals.
• Different hardwoods will impart a variety of flavors. Do some experimenting to find the type
of hardwood, or combination of hardwoods, that you like best. Start with the lowest amount of
wood chunks recommended—more can be added to suit your own taste. Some experimenting
will be necessary to find the amount of smoke flavor you prefer. (Use pieces of wood
approximately 2" x 3" in size.)
• By keeping records of your smoke-cooking experiences—a beginner can quickly become an
expert. Notes you make will be an invaluable aid in your future endeavors. By referring to your
notes at a later date you will be able to repeat your successes.
• Smoke-cooked foods look different than oven cooked foods—they may be pink or red when
completely cooked. A good meat thermometer is the most accurate way to determine the
internal temperature of large cuts of meat.
• Beer, wine, cola, fruit juices, marinades, herbs and spices can be combined with water, in the
waterpan, to give additional flavor to your food.
• Meat can be smoke-cooked without curing, or it can be cured before smoking with either a
dry cure or in a brine.

13
Brine Cure
Salting, or curing, reduces the moisture content of meat, retards formation of bacteria and adds
flavor as it is absorbed in the meat. When meats require 2 hours or less of curing they may be
kept at room temperature, otherwise they should be refrigerated.
Salt is the basic ingredient used in most seasonings and brines for smoking and curing foods.
Rock salt, pickling salt or canning salt are less expensive to use than iodized table.
Sugar is also a basic ingredient used in brines and dry cures—it is used during curing to
counteract the effects of salt. Sugar can be in the form of white or brown sugar, honey,
molasses or syrup—each imparts its own flavor.
Seasoning is more or less a matter of personal taste—spices can be used during or after the
curing process to give additional flavor to the meat or fish.
Stone crocks and glass or plastic containers are ideal containers for use in brining or storing
leftover brine. (Never use metal containers.)
Meat should be completely submerged in the brine. A weighted plate will be helpful to keep the
meat from coming to the surface of the brine.
Contents of the brine solution should be stirred occasionally with a wooden spoon. This is
called overhauling. When overhauling a large container of meat it is best to remove the meat
from the container, stir the brine, put meat back in container and pour the brine over meat,
weighing it down to keep meat completely submerged in the brine.
After a piece of meat or fish is removed from the brine solution it should be given a quick rinse
in fresh water and dried before smoking.
Sweet Pickle Brine
1 gal. water
21⁄2cups salt
1⁄3cup light brown sugar
1 tablespoon Liquid garlic
1 oz. pickling spices
Basic Brine
1 quart of water
1⁄2cup of salt
1⁄2cup light brown sugar
1⁄2teaspoon Liquid garlic
1⁄2teaspoon pepper
Dry cures can be used instead of a brine
solution. They are applied in a dry form
directly to the surface of the meat or fish.
Meats should be kept at 35° during dry
curing. Foods should be rinsed in fresh
water and dried before smoking.
Basic Dry Cure
2 cups salt
1⁄2cup sugar
Add spices and seasonings of your choice
to this mixture. Start with 1⁄2teaspoon of
each—experiment to find the combinations
you like best with the meat and fish you
smoke.

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Beef Roast,
Beef Brisket 3-4 lbs. Full 2 4-5 hrs. 4-6 145° rare
Lamb Roast,
Venison 5-7 lbs. Full 2 5-6 hrs. 4-6 160° med
Large cuts
of game 7-9 lbs. Full 2 6-8 hrs. 4-6 170° well
Beef ribs Full grill Full 1 3-4 hrs. 2-4 160° well
Beef Weight Water Charcoal Cooking Wood Internal
Pan Layers Time Chunks Temp
Pork Roast 3-4 lbs. Full 2 5-6 hrs. 4-6 160° med
4-8 lbs. Full 2 6-8 hrs. 4-6 170° well
Pork Ribs Full grill Full 1 4-6 hrs. 4-6 160° med
170° well
Pork Chops Full grill Full 1 2-3 hrs. 2-4 160° med
170° well
Fresh Ham 10-18 lbs. Full 2 8-12 hrs. 6-8 160° med
Whole 170° well
Whole Ham 10-14 lbs. Full 1 3-4 hrs. 4-6 140° med
Cooked
Smoking Cooking Charts
Please note: The amount of wood chunks, water or charcoal is not indicated in each recipe.
Please refer to this chart.
• The cooking times listed in the charts are for foods that have been completely thawed.
• Add 12 to 14 briquettes every 11⁄2hours. When coals are added check the waterpan and add
water as necessary to fill pan. Use door on front of unit to add charcoal or water.
Pork Weight Water Charcoal Cooking Wood Internal
Pan Layers Time Chunks Temp

15
Poultry Weight Water Charcoal Cooking Wood Internal
Pan Layers Time Chunks Temp
Small whole Full grill Full 1 1 1⁄2- 3 hrs. 2-4
Fillets Full grill Full 1 1 1⁄2- 3 hrs. 2-4
Large whole 3-6 lbs. Full 1 3-4 hrs. 2-4
Lobster,
Shrimp Full grill Full 1 1 hr. 2-4 firm/pink
Cut up 1-4 fryers Full 1 3-4 hrs. 2-4 180° well
Whole 1-4 fryers Full 2 4-5 hrs. 2-4 180° well
Whole 5 lbs. roaster Full 2 5-6 hrs. 2-4 180° well
Turkey 8-12 lbs. Full 2 7-8 hrs. 6-8 180° well
Unstuffed 12-18 lbs. Full 2 8-10 hrs. 6-8 180° well
Duck 3-5 lbs. Full 2 4-6 hrs. 2-4 185° well
Pheasant 3-5 lbs. Full 2 4-6 hrs. 2-4 185° well
Goose 8-10 lbs. Full 2 7-8 hrs. 4-6 185° well
Flakes
with a
fork.
• Always use hot water to fill or replenish the water pan. You might find that a watering can
works well.
• If your fire seems to be fizzling out—take the door on the front of the smoker off for a short
period of time. The additional oxygen will get the fire going again.
Fish Weight Water Charcoal Cooking Wood Internal
Pan Layers Time Chunks Temp

16
Pork Roast
1 rolled pork loin roast, 5-6 lbs.
1 garlic clove, cut into slivers
1⁄2teaspoon celery salt
1⁄2teaspoon rosemary
1⁄2teaspoon sweet basil
1⁄4teaspoon pepper
1 teaspoon caraway seed
Make small slits in top of roast and insert a garlic sliver in each slit. Combine seasonings and
sprinkle over roast. Place meat in center of cooking grill. Cover and smoke-cook about 6 hours
or until done.
Barbecued Pork Roast
4 lbs. pork back ribs or spareribs
1⁄4cup molasses
1⁄4cup Soy sauce
1⁄4cup vinegar
1⁄3cup prepared mustard
2 teaspoons Worcestershire sauce
1⁄2teaspoon hot pepper sauce (more if desired)
Place ribs in a plastic or glass dish. Combine remaining ingredients and pour over ribs. Cover
and refrigerate 5 hours or overnight. Turn ribs occasionally to completely coat with marinade.
Remove ribs from marinade and place on the cooking grill or in a rib rack. Cover and
smoke-cook 41⁄2to 5 hours or until done.
Pork Tenderloin Tarragon
2 whole pork tenderloins
1⁄2cup white tarragon vinegar
1 teaspoon Worcestershire sauce
2 teaspoons soy sauce
1 teaspoon dried tarragon
Place pork tenderloins in a shallow glass or plastic dish. Combine remaining ingredients and
pour over meat. Cover with plastic wrap and refrigerate 3 to 4 hours. Turn meat in marinade
occasionally. Place pork tenderloins on cooking grill. Pour marinade over meat allowing excess
to drain into the water pan. Smoke-cook 3 to 4 hours. Serve with pineapple sauce.
Pineapple Sauce:
Combine equal parts of drained crushed pineapple and sour cream.
Approximately 8 oz. of each.

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Smoked Glazed Ham
1 fully cooked ham, 10-14 lbs.
Whole cloves
1 quart apple cider
Remove any rind left on ham and score fat diagonally to give a diamond effect. Insert a whole
clove in center of each diamond. Place ham fat side up on cooking grill. Pour apple cider over
ham allowing excess to go into water pan. Cover and smoke-cook 3-4 hours brushing with
glaze occasionally during the last hour of cooking time.
Glaze
1 – 9 oz. jar currant jelly
1⁄4cup orange juice concentrate, undiluted
1 teaspoon prepared horseradish
1 teaspoon dry mustard
1 teaspoon lemon juice
Combine all ingredients in a saucepan. Heat, stirring until jelly melts.
Smoked Fresh Ham
1 fresh ham, 6-7 lbs.
Sweet pickle Brine (page 7)
Brown sugar
Prepare sweet pickle brine. Brine ham for 3 days in brine. Remove from brine. Rinse ham in
cold water and pat dry with paper towel. Let ham dry in refrigerator for 1 day. Rub outside
surfaces of ham with brown sugar. Place ham in center of cooking grate. Cover and smoke
approximately 8 hours. May be served immediately, however, flavor is enhanced by refrigerating
a day or two before serving.

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Beef Ribs
2-3 lbs. beef back ribs
2 – 8 oz. cans tomato sauce
1⁄4cup red wine vinegar
2 tablespoons prepared mustard
1 tablespoon prepared horseradish
1 tablespoon instant minced onion
1⁄2teaspoon garlic powder
1⁄4teaspoon pepper
Place ribs in a shallow glass or plastic dish large enough to accommodate them in a single
layer. Combine remaining ingredients and pour over ribs. Turn meat over to completely coat with
marinade. Cover with plastic wrap and refrigerate at least 4 hours turning occasionally. Remove
ribs from marinade and place on cooking grill. Pour remaining marinade over ribs allowing
excess to drain into water pan. Smoke-cook 31⁄2to 4 hours.
Beef Brisket
1 beef brisket, 5-6 lbs.
1 envelope dry onion soup mix
2 tablespoons port wine
2 cups barbecue sauce
Combine soup mix and wine to make a paste. Spread over surface of the brisket. Allow brisket
to stand at room temperature 2 hours before cooking. Add barbecue sauce to the water in the
water pan. Position brisket in center of cooking grill. Cover and smoke-cook approximately 6
hours or until tender.
Glazed Meat Loaf
11⁄2lbs. lean ground beef
1⁄2cup soda crackers, coarsely crumbled
1⁄2cup onion, finely chopped
2 eggs, slightly beaten
1 teaspoon salt
1⁄2teaspoon garlic salt
1⁄2teaspoon paprika
1⁄4teaspoon pepper
3⁄4cup milk
11⁄2cups sharp cheddar cheese, cubed
2 slices bacon
Combine ground beef, crumbs, onion and seasonings in a large bowl. Add eggs, milk and
cheese cubes; mix lightly until blended. Turn mixture into an aluminum foil pan and shape into
a loaf. Place bacon slices lengthwise on top of meat loaf. Position foil pan with meat loaf in
center of cooking grill. Smoke-cook 4 hours or until top of loaf feels firm.

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Glazed Hickory Smoked Turkey
1 turkey, thawed, 8-10 lbs.
Seasoned salt
1 tablespoon paprika
Stuffing:
2 oranges, cut into 8 chunks
Large onion, cut into 8 chunks
2-3 ribs celery, cut into 1" pieces
Rinse turkey thoroughly with cold water. Pat bird dry. Season inside and outside with
seasoned salt. Sprinkle outer surface with paprika. Stuff turkey with orange, onion and celery
chunks alternating the three different items. Fasten neck skin over back with skewer; lock
together. Place turkey on cooking grill. Cover with wine-jelly glaze during the last 2 hours of
cooking time.
Smoked Duck
1 duckling, thawed, 5 lbs.
6 green onions with tops, cut up
4-5 sprigs parsley
1 clove garlic, minced
1⁄3cup soy sauce
2 tablespoons lemon juice
2 tablespoons honey
Rinse bird thoroughly with cold water, drain and pat dry with paper toweling. Stuff cavity of
duckling with onion, parsley and garlic. Use a sharp knife to make a small cut between the wing
joints and breast to permit draining of excess fat during cooking. Lock wings behind back and
tie legs and tail together. Fasten neck skin over back with a skewer. Heat soy sauce, honey and
lemon juice, in a saucepan, to make a glaze. Place duckling in center of cooking grill. Cover
and smoke-cook 5-6 hours until done. Brush duckling with glaze occasionally. Serve with plum
sauce.
Plum Sauce
1 – 16 oz. can purple plums
1⁄4teaspoon orange peel, grated
3 tablespoons orange juice
2 tablespoons sugar
1⁄4teaspoon cinnamon
1⁄2teaspoon Worcestershire sauce
Drain plums reserving 1⁄4cup syrup. Force plums through a sieve. Combine plum puree and
reserved plum syrup with remaining ingredients in a saucepan. Heat to boiling; reduce heat
and simmer 15 minutes.
Glaze:
1⁄2cup currant jelly
1⁄2cup port wine
Combine currant jelly and wine in a saucepan
and cook over medium low heat stirring
constantly until jelly is melted. If glaze gets
too sticky during use, reheat it.

20
Cornish Hens
2 to 4 Cornish game hens, about 1 lb. each
Seasoned salt
Lemon pepper
1 large carrot, cut into julienne strips
1 medium onion, cut into wedges
Madeira Wine Sauce
Wash Cornish hens thoroughly with cold water and pat dry with paper toweling. Season inside
with seasoned salt and lemon pepper. Put carrot strips and onion wedges inside each hen. Lock
wings behind the back and tie legs together securely. Wrap a bacon strip around each hen and
secure with a toothpick. Sprinkle with lemon pepper and seasoned salt. Place hens on cooking
grill. Cover and smoke-cook 3 hours or until done. Baste with Madeira wine sauce during last
15 minutes of cooking time. Serve with remaining sauce.
Madeira Wine Sauce
1 cup crabapple jelly
1⁄2teaspoon ginger
1⁄4teaspoon salt
1⁄4cup Madeira Wine
1 orange peeled, cut orange peel into 3" julienne strips
Combine jelly, ginger, salt and wine. Cook over low heat until jelly melts; add orange strips and
simmer for 2 minutes.
Smoked Turkey
1 turkey, 12 lbs. completely thawed
Sweet Pickle Brine (see page 7)
Maple syrup
Rinse turkey thoroughly with cold water, drain and pat dry. Prepare sweet pickle brine. Brine
12 lb. turkey for 3 days. Remove from brine, rinse thoroughly in cold water and pat dry. Allow
to dry in refrigerator for 24 hours. Lock wings behind back and tie legs and tail together. Baste
bird with maple syrup before putting in the smoker and every 2 hours during smoking. Position
turkey on cooking grill. Smoke-cook 7 hours or until done. Cool turkey in the refrigerator for
24 hours before serving to enhance the smoked flavor. Turkey may be served immediately if
you wish.
Brine:
8-12 lb. bird — 3 days
13-16 lb. bird — 4 days
17-22 lb. bird — 5 days